online plant performance improvement solutions
TRANSCRIPT
Online Plant Performance Improvement Solutions
Suryaprakash DIGAVALLI
Owner and Principal Consultant
ENOPT Energy & Optimization Consultants Pte Ltd
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
PROFILE
Chemical Engineer with 17+ years experience
Operational experience with Refinery, Gas Plants and Petrochemical Plants
Mathematical model development
Certified Energy Auditor from Bureau of Energy Efficiency, India
Certified ISO 50001 – Energy Management Systems Lead Auditor
Advanced Diploma in Business Management
Key account management experience for large oil company in Middle-East
2EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
SERVICES PROFILE
EnMS ISO 50001 implementation guidance
Detailed energy audits for asset performance improvement
Process and Utility optimization
Situational Analysis and Scoping studies
Benchmarking studies
Data validation and reconciliation services for production and yield accounting
Strategic sensor placement during FEED stage
Training on process operations and performance monitoring
3EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Preamble
Management concern over energy efficiency
❑ “have we operated as well as we could?”
❑ “how can we improve ?”
Traditional energy reporting
❑ Monthly reporting of energy indices or specific energy consumption
❑ Fact reporting
❑ Does not often gives direction on action!
Our mantra – “Empower the Engineers and Operators”
4EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Reducing EI – A Continuous challenge
5EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Energy Savings
Energy Savings in plant are typically achieved in two ways:
❑ Optimization with no hard changes to the plant. Low investment and 2-5% reduction in overall energy consumption. UTILITY OPTIMIZATION
❑ Revamps and debottlenecking – where plant design is changed. High investment and 15+% reduction in overall energy consumption. PINCH ANALYSIS AND HEAT INTEGRATION
We advocate – “Rational Use of Energy and Resources”
6EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Energy Savings
Energy Savings in plant are typically achieved in two ways:
❑ Optimization with no hard changes to the plant. Low investment and 2-5% reduction in overall energy consumption. UTILITY OPTIMIZATION
❑ Revamps and debottlenecking – where plant design is changed. High investment and 15+% reduction in overall energy consumption. PINCH ANALYSIS AND HEAT INTEGRATION
We advocate – “Rational Use of Energy and Resources”
7EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Objectives and Targets
Asset energy performance benchmarking
Unit-wise performance benchmarking
Optimize hot and cold utilities with a direction to reach the theoretically possible minimum energy requirements
Composite curves exploitation to deploy any possible heat and power systems
Minimize loading of penalty exchangers if not eliminating them for energy savings in operation
Validate the facility design for sustainable energy efficiency
8EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Pinch analysis for heat integration
Energy Converters
Boilers
Waste heat recovery
CGTs
Etc.
Energy Consumers
Compressors
Pumps
Heat exchangers
Etc.
9EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Minimum Energy Requirements and Targets
Graphical representation
❑ Composite curves
Pinch point divides the process into two sub systems
❑ Above pinch point : Energy deficit
❑ Below pinch point and above ambient T°: Energy excess
Gives guidelines for process improvements
❑ Actions are taken according to the pinch point location
❑ Column pressure, reaction temperatures, etc.
Energy saving technologies
❑ i.e. heat pumps, air preheaters, oxygen enrichment, etc.
Quality of the utilities
❑ Steam network, primary energy, refrigeration cycles
10
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Conventional composite curves
11
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
ICC – better visibility
0
200
400
600
800
1000
1200
0 100 200 300 400 500 600 700 800
Adju
sted T
em
pera
ture
, deg F
Enthalpy, MMBtu/h
Integrated Composite Curves
12
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Energy Savings
Energy Savings in plant are typically achieved in two ways:
❑ Optimization with no hard changes to the plant. Low investment and 2-5% reduction in overall energy consumption. UTILITY OPTIMIZATION
❑ Revamps and debottlenecking – where plant design is changed. High investment and 15+% reduction in overall energy consumption. PINCH ANALYSIS AND HEAT INTEGRATION
We advocate – “Rational Use of Energy and Resources”
13
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Long-term strategic planning (years)
budgeting
contract evaluation/negotiation
evaluation of future investments
Short-term tactical planning (months)
meet contractual commitments
observe equipment maintenance schedules
Operational optimisation
reduce daily costs
typical benefits:
2-3% reduction of energy consumption for well-managed plants
up to 10-15% reduction of energy consumption for other plants
Multiperiod – Utilities management
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Dynamic demands, prices
Steam turbines
Heat recovery
Gas TurbinesBoilers
Power lines
Steam lines
Fuel lines
Electricity
Steam
Fuels
Chemical plants
External suppliesPlant demands
Plant generation
DRIVERS Pressure on energy cost & emissions
reductions
Impact of energy market deregulation – more contract flexibility
Increasing volatility in demand from client plants
COMPLEXITY (Potentially) large number of optimisation
decisions
fuel selection
device on/off status (boilers, turbines, …)
routing
Mixed continuous/discrete decisions
Site utilities management
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Utility Optimization
Equipment Optimized
❑ Boiler steam production
❑ Cogen GT power gen / HRSG steam production
❑ Choice of steam turbine / motor driven pumps and compressors
❑ Steam desuperheating, letdown and venting
❑ Steam Turbine extraction or condensing mode
❑ Amount of export or import electricity, contracts etc.
Utilities Optimized
❑ Steam – all pressure levels
❑ Boiler feed water, Condensate and Demin
❑ Fuel gas, Imported gas
Optimized to Minimum Cost of Fuel, Water and Import Power 16
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Utility Optimization Equipment constraints
Equipment Min and Max Constraints
❑ Pump flows
❑ Boilers loads
❑ GT / ST loads
Equipment Availability
❑ Mandatory(for operational reasons)
❑ Not available (in maintenance)
❑ Optimizable (free for the Optimizer to choose)
System Constraints eg
❑ Turndown capacity eg Boilers
❑ Min power export to grid (contractual)
❑ Min steam flows between production areas (process constraints)
17EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Challenges
Measurement data availability
Inconsistencies in data
Operator action tracking
Changing contracts and utility prices
Multiple decisions to make with cross subsidies
❑ Steam – all pressure levels
❑ Boiler feed water, Condensate and Demin
❑ Fuel gas, Imported gas, LPG vaporization, H2 mains
Optimized to Minimum Cost of Fuel, Water and Import Power
18
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
www.belsim.com
DVR PrinciplesDVR Optimization & Calculation
10.16PenaltyPenaltyPenalty
)σ(y
yyMinPenaltyMinObjective
CB
i
2
i
*
ii
i
i
A=++=
−==
Mass balance:
35 – 21 – 10 = 4 0
A:35
B:21
C:10
M:35
σ:2.10
P:7.41
R:32.08
M:21
σ:1
P:1.68
R:21.66
R:10.42
M:10
σ:0.8
P:1.07
A
B
C
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Utility Optimization
20EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Typical results of Utility Optimization
1,0
1,2
1,4
1,6
1,8
2,0
2,2
2,4
1-Jan 8-Jan 15-Jan 22-Jan 29-Jan
Uti
lity
Co
st,
Millio
ns IN
R
Overall Utility Cost
Current
Optimized
Avg savings
around 7%
Est. Potential Benefit 30 Crores INR/ Annum
21EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Differentiators
Data reconciliation as a precursor to optimization to ensure healthy values flow into optimizer eliminating GIGO scenario
MINLP solver usage to ensure the loading is globally optimal and not local optima
Robust automated structure with a few clicks for the solution
Full fledged training and inhouse maintaining capabilities imparted.
22EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
References
Saudi Aramco Gas plants Utility systems
Indian Oil refinery
23EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Timelines
With full fledged reconciliation and utility optimization the project is normally around 6 months and 2 engineers
Without reconciliation and simple optimization algorithms for operational guidance would be around 6 months and 1 engineer
24EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Operational frequency
Recommended to run the tool once per shift to get the valid set points for optimal operation
Reconciliation and calibration tool could run once every hour to automate performance monitoring and cater to the optimization algorithm with the corrected data.
25EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
Tool integration
The tool is supposed to interface with the plant historian system for its automated operation
This works on historical data and hence no DCS integration is envisaged.
This tool is intended to be decision support system and would be in the custody of technologist and operations supervisor
The operations supervisor could run and supply the set points for optimal operation
The technologist could run this tool to monitor performance of the big equipment and recommend operational changes. Further he could run what-if scenarios and arrive at profitable recommendations
26EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
BENEFITS…
❑ Sustainable energy savings
❑ Optimal plant loading to improve asset reliability
❑ Better operational picture of the plants and depiction of lost opportunity cost
❑ Energy awareness trainings for a motivated workforce
❑ Online running applications deployment with very low maintenance / intervention
❑ Lower carbon foot print
❑ Confident and profitable operations
27
EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127
HAPPY TO ASSIST
THANK YOU
FOR YOUR
TIME & ATTENTION
Phone: +65-911-718-25 [SG]
Email: [email protected]
Skype: surya18881
28EnOpt Energy and Optimization Consultants Pte. Ltd., #24-01, Regus Vision Exchange, 2 Venture Drive, SINGAPORE 608526 Ph: +65 6914 9127